Tamper Resistant Lock System

This application claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 63/653,331, filed May 30, 2024, entitled “HUB BLOCKER,” which is incorporated herein by reference in their entirety.

The field is related to door lock systems.

Door lock systems generally include lock bodies and lock trim assemblies. The lock bodies may include bolt assemblies with a deadbolt and/or latch configured to move between engaged and disengaged position(s). In the engaged position, the deadbolt/latch is generally received into a pocket in the door jamb to prevent opening of the door. In the disengaged position, the deadbolt/latch is retracted into the lock body, allowing the door to be opened.

The deadbolt and/or latch is moved to the disengaged positions by actuation of a lock trim actuator (handle, knob,) of a lock trim assembly. The lock trim assembly generally includes a lock spindle operatively connected to the lock trim, such that rotation of the lock trim actuator about a lock axis rotates the lock spindle about the lock axis.

The lock spindle is operatively connected to components of the deadbolt assembly and/or latch assembly, such that the deadbolt and/or latch is moved to the retracted position when the lock spindle is rotated about the lock axis. The deadbolt assembly and/or latch assembly generally includes at least one spindle cam configured to engaged with the lock spindle, such that the spindle cam rotates with the lock spindle, and a transmission unit which engages with the spindle cam and the deadbolt/door latch so that the deadbolt/door latch retracts when the spindle cam rotates.

Door lock systems are generally locked by preventing rotation of the lock spindle. This may be accomplished by preventing rotation of the lock trim actuator, or by decoupling the lock spindle from the lock trim actuator, such that rotating the lock trim actuator does not rotate the lock spindle.

According to some aspects, a lock body is provided, the lock body comprising a bolt assembly and a spindle cam latch assembly. The bolt assembly comprises a spindle cam configured to engage with a lock spindle of a lock trim assembly, such that rotating the lock spindle about a lock axis rotates the spindle cam about the lock axis. The spindle cam latch assembly comprises a cam latch configured to move between an engaged position, where the cam latch engages with the bolt assembly to prevent rotation of the spindle cam about the lock axis, and a disengaged position, and a biasing mechanism configured to bias the cam latch towards the engaged position. The cam latch is configured to selectively engage with a projection extending from the lock trim assembly, such that when the lock trim assembly is engaged with the lock body, the projection extends into the lock body and moves the cam latch to the disengaged position, and when the lock trim assembly is disengaged from the lock body, the projection is removed from the lock body and the cam latch is moved to the engaged position by the biasing mechanism.

According to some aspects, a door lock system is provided, the door lock system comprising a lock trim assembly and a lock body. The lock trim assembly comprises a lock trim actuator and a lock spindle configured to rotate about a lock axis, and a projection extending from the lock trim assembly. The lock body is configured to selectively engage with the lock trim assembly. The lock body comprises a bolt assembly comprising a spindle cam configured to engage with the lock spindle; such that rotating the lock spindle about the lock axis rotates the spindle cam about the lock axis, and a spindle cam latch assembly comprising a cam latch configured to move between an engaged position, where the cam latch engages with the latch assembly to prevent rotation of the spindle cam about the lock axis, and a disengaged position, and a biasing mechanism configured to bias the cam latch in the engaged position. The cam latch is configured to selectively engage with the projection extending from the lock trim assembly, such that when the lock trim assembly is engaged with the lock body, the projection extends into the lock body and moves the cam latch to the disengaged position, and when the lock trim assembly is disengaged from the lock body, the projection is removed from the lock body and the cam latch is moved to the engaged position by the biasing mechanism.

According to some aspects, a lock body is provided, the lock body comprising a bolt assembly comprising a spindle cam configured to engage with a lock spindle of a lock trim assembly, such that rotating the lock spindle about a lock axis rotates the spindle cam about the lock axis, and a spindle cam shutter assembly. The spindle cam shutter assembly comprises a cover plate configured to move between a cover plate engaged position and a cover plate disengaged position, wherein the cover plate is configured to cover the spindle cam in the cover plate engaged position, and a blocker configured move between a blocker engaged position and a blocker disengaged position, wherein the blocker is configured to hold the cover plate in the cover plate engaged position when the blocker is in the blocker engaged position. The cover plate is configured to be held in the cover plate disengaged position by a portion of the lock trim assembly, such that when the lock trim assembly is disengaged from the lock body, the cover plate moves to the cover plate engaged position.

According to some aspects, a door lock system is provided, the door lock system comprising a lock trim assembly and a lock body. The lock trim assembly comprises a lock spindle configured to rotate about a lock axis. The lock body is configured to selectively engage with the lock trim assembly and comprises a bolt assembly and a spindle cam shutter assembly. The bolt assembly comprises a spindle cam configured to engage with the lock spindle, such that rotating the lock spindle about the lock axis rotates the spindle cam about the lock axis. The spindle cam shutter assembly comprises a cover plate configured move between a cover plate engaged position and a cover plate disengaged position, wherein the cover plate is configured to cover the spindle cam in the cover plate engaged position, and a blocker configured move between a blocker engaged position and a blocker disengaged position, wherein the blocker is configured to hold the cover plate in the cover plate engaged position when the blocker is in the blocker engaged position. The cover plate is configured to be held in the cover plate disengaged position by a portion of the lock trim assembly, such that when the lock trim assembly is disengaged from the lock body, the cover plate moves to the cover plate engaged position.

It should be appreciated that the foregoing concepts, and additional concepts discussed below, may be arranged in any suitable combination, as the present disclosure is not limited in this respect. Further, other advantages and novel features of the present disclosure will become apparent from the following detailed description of various non-limiting embodiments when considered in conjunction with the accompanying figures.

As discussed above, door lock systems may include lock bodies with bolt assemblies configured to hold a door closed, and lock trim assemblies configured to actuate the bolt assemblies. The bolt assemblies may include any suitable bolts, such as deadbolts or latches. Door lock systems are generally locked by preventing rotation of the lock spindle, such as by preventing rotation of the lock trim, or by decoupling the lock spindle from the lock trim, such that rotating the lock trim actuator does not rotate the lock spindle.

However, locking a door lock system by preventing rotation of the lock spindle may make the lock susceptible to forced entry. If an intruder can forcibly remove the lock trim assembly (e.g. by drilling out fasteners, prying the lock trim assembly away, cutting the lock trim assembly away, etc.), a spindle cam of the bolt assembly will be accessible to the intruder. The intruder may then simply insert a rod (e.g. a screwdriver) into the spindle cam and rotate the rod to actuate the spindle cam, retracting the latch/deadbolt.

The inventors have therefore recognized an advantage to preventing retraction of the deadbolt/latch when a lock trim assembly is removed from the lock body. Accordingly, aspects disclosed herein are directed to arrangements for preventing actuation of the spindle cam.

In some embodiments, the lock body may include a cam latch assembly that is deployed to prevent spindle cam rotation. The cam latch assembly may include a cam latch configured to be in a disengaged position when a lock trim assembly is engaged with the lock body, and may move to an engaged position when the lock trim assembly is disengaged from the lock body. In the engaged position the cam latch may engage with the spindle cam and prevent rotation of the spindle cam about the lock axis.

In some embodiments, the lock trim assembly includes a projection extending from the lock trim assembly. The projection may be configured to extend into the lock body and contact the cam latch to move the cam latch to the disengaged position when the lock trim assembly is attached to the lock body. When the lock trim assembly is removed from the lock body, the projection may be removed from the lock body and no longer contact the cam latch, allowing the cam latch to be moved to the engaged position. In some embodiments, a biasing mechanism biases the cam latch to the engaged position when the projection is removed.

In some embodiments, the lock body may include a spindle cam shutter assembly. The spindle cam shutter assembly may include a cover plate configured to be in a disengaged position when a lock trim assembly is engaged with the lock body, and may move to an engaged position when the lock trim assembly is disengaged from the lock body. In the engaged position, the cover plate may cover the spindle cam so as to prevent external access to the spindle cam. In some embodiments, the cover plate may be supported in the disengaged position via a projection extending from the lock trim assembly and into the lock body when the lock trim assembly is engaged with the lock body. When the lock trim assembly is disengaged from the lock body, the projection may be removed from the lock body, and may no longer support the cover plate, allowing the cover plate to move to the engaged position. In some embodiments, a portion of the lock spindle of the lock trim assembly is configured to support the cover plate in the disengaged position. When the lock trim assembly is disengaged from the lock body, the lock spindle may be removed from the lock body, and may no longer support the cover plate, allowing the cover plate to move to the engaged position. In some embodiments, the portion of the lock spindle which supports the cover plate in the disengaged position includes a rounded cross-sectional profile. In some embodiments the cover plate may move to the engaged position via gravity.

In some embodiments, the spindle cam shutter assembly may include a blocker configured to move to an engaged position with the cover plate and to hold the cover plate in the engaged position to prevent an intruder from jimmying the cover plate to the disengaged position to gain access to the spindle cam.

Turning to the figures, specific non-limiting embodiments are described in further detail. It should be understood that the various systems, components, features, and methods described relative to these embodiments may be used either individually and/or in any desired combination as the disclosure is not limited to only the specific embodiments described herein.

shows a partially exploded perspective view of a lock system with lock bodyand lock trim assembly.

Lock trim assemblymay be configured to be attached to a side of a door (e.g. an exterior side or an interior side). The lock trim assemblymay include lock spindleand lock trim actuator. Lock spindleand lock trim actuatormay be operatively connected, such that applying an external torque to the lock trim actuator(e.g. by grasping and rotating the lock trim actuator) rotates the lock spindleabout lock axis A. Lock spindlemay be configured to engage with spindle camof a deadbolt assemblyin order to actuate a deadboltof the deadbolt assembly, as discussed further below. While lock trim actuatoris shown as a handle in, any suitable lock trim actuator is contemplated, such as a knob or a motor.

In some embodiments, lock trim assemblymay include a locking mechanismconfigured to move between a locked position and an unlocked position. In the locked position, the locking mechanism may prevent activation of the deadbolt. This may be accomplished via any suitable locking mechanism, such as by prevention of rotation of the lock trim actuatorabout the lock axis A, thereby preventing rotation of the lock spindleabout the lock axis A, or by decoupling the lock spindlefrom the lock trim actuator, such that rotation of the lock trim actuatorabout the lock axis Adoes not rotate the lock spindle about the lock axis. Such suitable locking mechanisms may include a lock cylinder, an electromechanical lock (e.g. a lock actuated via biometrics, passcodes, RFID, etc.), or any other conventional locking mechanism.

shows an exploded perspective view of a lock bodyof a door lock system.show a side view of lock bodywith a deadbolt in engaged and disengaged positions, respectively.

As mentioned above, the lock spindlemay be operatively connected to a deadbolt assemblyof the lock body, such that actuating the lock trim actuatorbetween an engaged position and a disengaged position moves the deadboltbetween an engaged position, where the deadboltis received into a pocket of a door jamb to prevent opening of the door (as shown in), and a disengaged position, where the deadboltis retracted into the lock bodyto allow the door to be opened (as shown in).

Deadbolt assemblymay include a spindle camconfigured to engage with lock spindle, such that spindle camrotates about lock axis AL in a first direction (e.g. counter-clockwise in) from the engaged position to the disengaged position as the lock spindlerotates about the lock axis AL in the first direction. As spindle camrotates, a cam armof the spindle cam may contact transmission unit, moving the transmission unit from the engaged position to the disengaged position. The transmission unitis operatively connected to the deadbolt, such that the deadboltmoves from the engaged position to the disengaged position as the transmission unitmoves to the disengaged position.

In some embodiments, cam armis configured to only push the deadboltto the disengaged position, such that the deadboltdoes not return to the engaged position when spindle camis returned to the engaged position. The deadboltmay be held in the disengaged position via a separate trigger mechanism (not shown). Actuation of the trigger mechanism may release the deadbolt and may allow biasing mechanismto bias the deadboltto the engaged position. The trigger mechanism may be configured to be actuated via contact between the trigger mechanism and a portion of the door jamb. Such a deadbolt assembly is disclosed in U.S. Pat. No. 11,702,864, which is incorporated by reference herein.shows a side view of lock bodywith a cam latch assembly in an engaged position. As discussed above, the inventors have recognized that it may be desirable to prevent rotation of the spindle camabout lock axis A. when the lock trim assemblyis removed from the lock body, in order to prevent an intruder from being about to actuate the spindle camand retract the deadboltafter forcibly removing the lock trim assembly. The lock bodymay therefore include a spindle cam latching assemblyconfigured to prevent rotation of the spindle camwhen the lock trim assemblyis removed. The spindle cam latching assembly may include a cam latchconfigured to move between an engaged position and a disengaged position. In some embodiments, as seen in, the cam latchmay be configured to rotate about an axis Ac between the disengaged and engaged positions. In the disengaged position, as seen in, the cam latchmay be disengaged from any portion of the deadbolt assembly. This allows each component of the deadbolt assemblyto move between engaged and disengaged positions when a torque is applied to the spindle camvia lock spindle, and allows the deadboltto be retracted, as seen in.

In the engaged position, the cam latchmay engage with the spindle cam, the transmission unit, or the deadboltand prevent movement of any of these components of the deadbolt assembly. For instance, as seen in, a hook portionof cam latchmay be configured to interlock with a tabon the spindle cam. When the hook portionis interlocked with tab, a torque applied to the spindle camto rotate the spindle cam in the first direction (e.g. the counterclockwise direction in) will be prevented from rotating the spindle camin the first direction, thus preventing the armfrom moving the transmission unitto the disengaged position, and preventing the deadboltfrom being retracted.

In some embodiments, the cam latchmay be biased towards the engaged position via biasing mechanism. In some embodiments, biasing mechanismmay be a torsion spring, with spring legsA andB. Spring legA may be configured to contact a stationary portion of the lock body, while spring legB may be configured to contact a portion of the cam latch. The torsion spring's stiffness may cause the legsA andB to extend away from each other, biasing the cam latchto the engaged position.

In some embodiments, the lock trim assemblymay include a projectionconfigured to extend into the lock bodywhen the lock trim assemblyis attached to the lock body, and to be removed from the lock bodywhen the lock trim assemblyis removed from the lock body. When projectionextends into the lock body, projectionmay be configured to contact the cam latchand hold the cam latchin the disengaged position. For instance, as seen in, the projectionmay contact lever armof the cam latch. Lever armmay include a slanted camming surface, such that when the slanted camming surfaceis contacted by projectionas projectionis being inserted into the lock body, the projectionapplies a force to lever armperpendicular to the direction of travel of the projection. This perpendicular force creates a torque on the cam latchthrough the lever arm and rotates the cam latchabout the axis of rotation Ato the disengaged position. When the lock trim assembly is removed from the lock body, the projectionmay be removed from the lock body. This allows the biasing mechanismto bias the cam latchinto the engaged position, preventing rotation of the spindle camand operation of the deadbolt assemblyfrom the side of the door the lock trim assemblywas removed from. In some embodiments, the projectionextends from the lock trim assemblyapproximately parallel to the lock spindle. In some embodiments, the projectionincludes a camming surface configured to correspond to camming surfaceof lever arm. In some embodiments, projectionis a support post of the lock trim assemblyconfigured to allow the lock trim assemblyto be secured to the door and to corresponding lock trim assembly on the other side of the door.

In some embodiments, it may be desirable to allow the deadbolt assemblyto be actuated from an opposite side of the door (e.g. the unsecured side/interior side) even if the lock trim assemblyhas been removed. The lock bodymay therefore include a second spindle camconfigured to engage with a lock spindle of a corresponding lock trim assembly attached to the opposite side of the door. Second spindle cammay be configured to rotate about lock axis Abetween engaged and disengaged positions independent of spindle cam. When second spindle camrotates to the disengaged position, an armof second spindle cammay contact the transmission unitand unlatch the deadbolt. Because second spindle cammay rotate independent of spindle cam, the deadbolt assemblymay still be actuated from the opposite side of the door even if the spindle camis prevented from rotating by cam latch assembly. In some embodiments, it is contemplated that the lock bodymay include a second cam latch assembly configured to engage only with the second spindle cam. In this manner, removing the lock trim assembly from either side of the door lock system may prevent actuation of the deadbolt assemblyfrom that side of the door, while still allowing users on the other side of the door to open the door.

While the above embodiments disclose the cam latchrotating between the disengaged and engaged position, any suitable motion which allow the cam latch to move between engaged and disengaged positions is contemplated. For instance, as seen in, an alternative lock bodymay include a cam latchconfigured to slide between a disengaged position (), and an engaged position (). Cam latchmay include a projectionconfigured to interlock with a slotin the spindle cam. Cam latchmay be biased to the engaged position via biasing mechanism, and projectionmay contact slanted camming surfaceto slide the cam latchto the disengaged position. Removing the lock trim assemblyfrom the lock bodymay remove the projectionfrom the lock body, allowing the biasing mechanismto bias the cam latchinto the engaged position.

shows a perspective view of a lock body.show spindle cam shutter assemblies of the lock bodyat various stages of engagement.

In some embodiments, the inventors have recognized that it may be desirable to prevent an intruder from being able to access the spindle cam in addition to or as an alternative to locking the spindle cam using a cam latch assembly.

In some embodiments, a lock bodymay include an outer coverand a spindle cam shutter assembly. Outer covermay have an openingto allow the lock spindleto be inserted into spindle cam, but may prevent any other access to spindle cam shutter assembly.

In some embodiments, the spindle cam shutter assemblyincludes a cover plateconfigured to move from a disengaged position to an engaged position. When the cover plateis in the disengaged position, as seen in, the spindle camis not blocked by the cover plate. This allows lock spindleto engage with the spindle camand actuate the deadboltusing one of the deadbolt assemblies discussed above, or any other conventional deadbolt assembly. In some embodiments, cover platemay be held in the disengaged position by projection(s)extending from lock trim assemblyinto lock body. In some embodiments, projection(s)are a support post(s) of the lock trim assemblyconfigured to allow the lock trim assemblyto be secured to the door and to a corresponding lock trim assembly on the other side of the door. In some embodiments, projectionis a separate projection from the support posts. In some embodiments, the cover plateis held in the disengaged position via contact between the cover plateand a portionof the lock spindle. In some embodiments, the portionof the lock spindle includes a rounded cross-sectional profile. Such a configuration may allow the lock spindleto rotate smoothly between engaged and disengaged positions while supporting the cover platein the disengaged position.

When the lock trim assemblyis removed from the lock body, the projection(s)and/or lock spindleare removed from the lock bodyand no longer holds the cover platein the disengaged position, allowing the cover plateto rotate to the engaged position shown in. In the engaged position, the cover plateblocks access to the spindle cam. In some embodiments, a biasing mechanism moves the cover plateto the engaged position. In some embodiments, the cover plates moves to the engaged position via gravity. In some embodiments, the cover plateis supported in the engaged position via support projection.

In some embodiments, it may be desirable to block the cover platein the engaged position to prevent an intruder from jimmying the cover plateto the disengaged position and gaining access to the spindle cam. The lock bodymay include a blocker, such as blocker plateconfigured to hold the cover platein the engaged position. As seen in, the blocker plate is supported in the disengaged position via contact between the cover plateand the blocker plate. When the cover platerotates to the engaged position, blocker platemay also be rotated to an engaged position. via a biasing mechanism, gravity, or any other suitable means. If an intruder were to attempt to jimmy the cover plate to disengaged position, as seen in, a surfaceof blocker platewill contact a surfaceof cover plate, preventing further movement of the cover plateto the disengaged position.

In some embodiments, blocker plateincludes a pawl(e.g. a corner of the blocker plate) configured to interlock with teeth (not shown) on the cover plate. Engagement between the teeth and the pawl may function like a ratchet, allowing rotation of the cover plateand blocker plateto the engaged positions, while preventing rotation of the cover plateand blocker plateto the disengaged positions via contact between the pawl and the teeth.

While the above embodiments disclose cover plate and blocker plate configured to rotate from the disengaged positions to the engaged positions, either of both of cover plate and blocker plate may be configured to slide from the disengaged positions to the engaged positions. Additionally, the blocker need not be a blocker plate, but may be any suitable mechanism which holds the cover plate in the engaged position.

For instance,show schematic representations of an alternative lock bodywith an alternative spindle cam shutter assemblyin disengaged and engaged positions respectively. Cover platemay be configured to slide along railsbetween the engaged position and disengaged positions. Cover platemay supported in the disengaged position via contact between the cover plateand the lock spindle, or via contact between the cover plateand some other projection extending from the lock trim assembly. When the lock spindle and/or projection are removed from lock bodywhen lock trim assemblyis removed from the lock body, the cover plate may slide to the engaged position, as seen in, and block access to the spindle cam. The cover platemay be held in the engaged position via at least one pin. Each pinmay be biased towards the engaged position via biasing mechanism, but held in the disengaged position via contact between the cover plateand a head of each pinwhen the cover plate is in the disengaged position. When the cover platemoves to the engaged position, the head of each pin no longer contacts the cover plate, allowing the biasing mechanism(s)to push the pin(s) to the engaged position. In the engaged position, a side of each pin may prevent the cover platefrom moving to the disengaged position via contact between the side of the pin and the cover plate.

While the above embodiments disclose lock bodies with deadbolt assemblies, any suitable bolt or latch mechanism configured to be received into pocket(s) of the door jamb is contemplated. For instance, any of the above deadbolt assemblies may be substituted for a latch assembly. Alternatively, a lock body could include a bolt assembly with both a deadbolt and a latch.

For instance,shows a side view of lock body, with a bolt assemblywhich includes both a deadboltand a door latch. Both the deadboltand the door latchmay be operatively connected to armof the spindle camvia transmission unit linkagesA andB, such that rotation of the spindle camfrom the engaged position to the disengaged position moves both the deadboltand the door latchfrom the engaged positions to the disengaged positions. Spindle cammay be operatively connected to lock spindleand lock trim actuator, such that rotation of the lock trim actuatorto the disengaged position via an external force (e.g. a user grasping and rotating the lock trim actuator), moves the lock spindleand the spindle camto the disengaged position.

Once the external force to the lock trim actuatoris removed (e.g. when a user lets go of the lock trim actuator), the lock trim actuator, lock spindle, and door latchmay be moved to the engaged positions using any suitable mechanism. For instance, a biasing mechanism (not shown), may be operatively connected any of the lock trim actuator, lock spindle, door latch, spindle cam, and transmission unit linkagesA andB, and configured to bias this component to the engaged position. Because all of these components are operatively connected, when the component operatively connected to the biasing mechanism is moved to the engaged position, the rest of these components will also be moved to their respective engaged positions.

In some embodiments, transmission linkageB is configured to only push the deadboltto the disengaged position, such that the deadboltdoes not return to the engaged position with the rest of bolt assembly. The deadboltmay be held in the disengaged position via a separate trigger mechanism (not shown). Actuation of the trigger mechanism may release the deadbolt and may allow biasing mechanismto bias the deadboltto the engaged position. The trigger mechanism may be configured to be actuated via contact between the trigger mechanism and a portion of the door jamb. Such a deadbolt assembly is disclosed in U.S. Pat. No. 11,702,864, which is incorporated by reference herein.

Lock bodymay include a cam latch assemblyconfigured to selectively engage with spindle camwhen the lock trim assemblyis removed to prevent the deadboltand the door latchfrom moving to the disengaged positions when the lock trim assemblyis removed. Cam latch assemblymay be substantially similar to any of the cam latch assemblies disclosed above.

While the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art. Accordingly, the foregoing description and drawings are by way of example only.